Nasty sqeaking/creaking... Bad ball joints?

TSB 05-14-3

What model year car are we dealing with? There is a Ford TSB that sounds like a match (if correct MY).

I had this same problem on my 2003. Try to reproduce by turning the wheel almost to the limits of travel. Then have a buddy slowly turn the wheel to the limit of travel. From under the car, look at the steering rack. You may notice it moving (straining) on the bushings. This is normal. However, you may also note that it squeaks at the same time.

I fixed it by replacing the steering rack bushings with stiffer model bushings and lubbing them well. The Ford TSB calls for the rack support tubes (through the K-member) to be replaced and re-torqued.

If the problem occurs only when braking, IMO it is more likely front suspension or ball joints.

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TSB 05-14-3

07/25/05

SQUEAK/CREAK NOISE FROM STEERING RACK
WHEN TURNING

FORD:
2002-2004 Mustang

This article supersedes TSB 04-24-8 to update the Action.

ISSUE
Some 2002-2004 Mustang vehicles may exhibit a squeak or creak type noise when turning.

ACTION
Replace both power steering gear tube brackets.
Refer to Workshop Manual Section 211-02 Steering Gear Mounting. Tighten the steering gear mounting fasteners to 52 lb-ft (70 N.m).

WMburns may've hit the spot. It's one of two possible problems. It's either the center sleeves on the steering rack mounts creeking .. or ball joints. Right now, I have a creeking sound coming from the front end (light, not that loud) that occurs mostly when I'm stepping on the brake and allmost at a full stop. Typically as the front end is moving down with a certain amount of force. And get it sometimes when I'm stopped and turn the wheel slowly. I have verified my ball joints on this one. Both wheels have a slight clunk of in out play top to bottom. And the creek is coming from the drivers side ball joint.

A couple years ago I had the problem with the steering rack. No matter how much I tightened the rack mounts, it still creeked like hell... just like you explain. It's the metal sleeves in the middle between the nut and bolt head. They start sliding sideways .. and new bushings and sleeves are the only fix. Of course, if you got oil or steering fluid leakage onto the bushings, you might want to remedy that first. The oil weakens the bushings over time.

The TSB applies to 2002-2004 MY. So it does not apply to you.

What happens if you bounce up/down on the suspension? Can the sound be reproduced?

What about the condition of the grease seals on the ball joints? Tie rod ends?

The trick here is to narrow this down. Condiser taking it somewheere for a repair "estimate". A pro may be able to nail this down much quicker.

Checking up on a post of yours back from september, I see you are somewhere around the 165k miles mark. Being that your OD is broke, and you do work on a daily basis, you've probably got around 170k miles or so. I'd say you were well due for balljoints to be replaced. It's that time. I'm around 160k or so. Maybe 145-150k. Don't know, my OD is broke also . My original OD broke at 100k in '04. The cluster I have now has been broke at 160k. I think going in and out of work where there are numerous HARD speedbumps killed my balljoints. Consider them especially if you hit a lot of hard bumps in the road.

Any way you can record the sound? I could tell you almost for certain if it's your ball joints just by hearing the noise when you push on the suspension. I'd come out and check it out for you, but you're well on the other side of the state by West Palm Beach.